CN111324980B - Lightweight hierarchical optimization design method for automobile structure - Google Patents
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Abstract
The invention relates to a lightweight hierarchical optimization design method for an automobile structure, which comprises the steps of firstly building a complete automobile finite element model, and then developing first-level optimization and second-level optimization based on the complete automobile finite element model; the first-level optimization firstly constructs a soft constraint model, then performs topological optimization analysis, optimizes the material distribution of the research object, optimizes the structural shape of the research object, finds out the region with concentrated strain energy in the soft constraint model, and optimizes the region with concentrated strain energy; and the second-level optimization firstly takes the finished automobile finite element model as an analysis object, executes simulation analysis, then establishes a transfer function of the control factor and the output performance, and completes the optimization of the control factor based on the transfer function to obtain an optimal solution. According to the lightweight hierarchical optimization design method for the automobile structure, provided by the invention, the problems of design redundancy or insufficient performance can be reduced through moderate lightweight; the vehicle performance can be fully correlated and improved, and the structure optimization effect is more obvious.
Description
Technical Field
The invention relates to the technical field of automobile lightweight, in particular to a lightweight hierarchical optimization design method for an automobile structure.
Background
The automobile is light, namely the weight is the lightest on the premise of ensuring the relevant performance, so that the mass and the fuel consumption of the whole automobile are reduced. The light weight is realized by three main ways: 1. the structure is light, namely a more reasonable structural design is adopted, and the method is also an economical and practical approach; 2. the material is light, namely, a light metal or nonmetal material with high strength and low density is adopted; 3. the process is light-weighted, i.e. by more advanced process technology.
The existing automobile structure light-weight technology takes the performances of modal, rigidity and the like in a 'hard constraint state' (boundary freedom degree is completely locked or released) of a research object monomer (a closing member and a body-in-white) as constraint conditions, and the minimum mass is an optimization target to realize light weight. The problem brought by the method is obvious, because the real constraint boundary of the research object cannot be effectively reflected, the relevance of the performance and the performance of the whole vehicle is not high, and even if the performance control of the research object in the single body hard constraint state is qualified, the performance of the research object in the state of the whole vehicle still can meet the problem that various performances do not reach the standard, so that the problems of design redundancy or insufficient performance can be caused.
Disclosure of Invention
The invention provides a light-weight hierarchical optimization design method of an automobile structure, aiming at the problem that design redundancy or performance insufficiency is caused by the fact that the existing light-weight technology of the automobile structure cannot effectively relate to and reflect the performance of the whole automobile, and the light-weight hierarchical optimization design method can realize the forward development of the light-weight of the automobile structure and can give consideration to the performance and the quality of the whole automobile.
The invention relates to a lightweight hierarchical optimization design method of an automobile structure,
firstly, building a finished automobile finite element model, and then developing first-level optimization and second-level optimization based on the finished automobile finite element model;
the first level of optimization comprises the following steps:
firstly, intercepting a research object on a finite element model of a finished automobile, and constructing a soft constraint model;
secondly, based on the soft constraint model in the first step, performing topological optimization analysis by taking the system-level performance index of the research object as a constraint condition and taking the minimum quality as an optimization target, and optimizing the material distribution of the research object;
step three, optimizing the shape of the soft constraint model optimized in the step two, and optimizing the structural shape of a research object;
step four, performing strain energy analysis on the soft constraint model optimized in the step three, finding out a region with concentrated strain energy in the soft constraint model, and optimizing the region with concentrated strain energy;
the second level of optimization comprises the steps of:
and 3, based on the transfer function in the step 2, optimizing the control factor by adopting a simulated annealing algorithm by taking the output performance not more than the design target value as a constraint condition and the quality minimum as an optimization target to obtain an optimal solution, and calling a finished automobile finite element model to verify the optimal solution.
Further, the second step is specifically: and (3) establishing a topological optimization design space based on the soft constraint model in the step one, performing topological optimization analysis by taking the system-level performance index of the research object as a constraint condition and taking the minimum quality as an optimization target, finding the optimal material distribution in the design space, reserving the material of the key part, and removing the material of the non-key part.
Further, the third step is specifically: and after the second step of optimization, removing materials of non-critical parts on the research object to form holes, and determining the shape of the holes with the best performance by moving or deforming the nodes of the finite element mesh to a new position and deforming the mesh and the nodes.
Further, in step four, the method for optimizing the region where the strain energy is concentrated includes adding a reinforcement member to the region where the strain energy is concentrated.
Further, the step 2 specifically comprises: and (3) establishing a transfer function of a control factor and an output performance based on a polynomial response surface method according to the simulation analysis result in the step (1), and performing precision verification on the transfer function by using an error analysis method.
Furthermore, the research object is a back door structure, the soft constraint model comprises a back door, a vehicle body back door frame and a back door and vehicle body connecting piece, the performance index of the research object comprises the bending mode and the torsion mode of the back door, and the material thickness parameter of the research object comprises the material thickness of an inner plate of the back door, the material thickness of an outer plate of the back door and the material thickness of a reinforcing piece; the whole-vehicle-level related performance of the research object comprises the vibration performance of a back door under the whole vehicle.
The invention discloses a hierarchical optimization design method of an automobile structure, which is divided into two levels, wherein the first level of optimization is as follows: based on the performance index of the research object in a soft constraint state, adopting a topological optimization technology to find the optimal material distribution, adopting a shape optimization technology to optimize the shape of the research object, and then adopting a strain energy analysis technology to identify and optimize the weak part of the research object; the second level of optimization is: and determining the optimal part material thickness of the research object by adopting a parameter optimization technology based on the related overall vehicle performance indexes. The first hierarchical optimization realizes strong association between the system-level performance of a research object and the performance of the whole automobile, and the hierarchical optimization realizes the lightweight of the automobile structure and can also give consideration to the performance of the whole automobile. According to the lightweight hierarchical optimization design method for the automobile structure, provided by the invention, the problems of design redundancy or insufficient performance can be reduced through moderate lightweight; compared with the structural optimization based on the performance under the 'hard constraint state', the invention can fully correlate and improve the performance of the whole vehicle, and the structural optimization effect is more obvious. The invention fully considers the performance index of the whole vehicle, achieves the effect of one-time design pair, avoids the performance problem of the whole vehicle, and reduces the risks of longer research and development period and increased research and development cost caused by later design change.
Drawings
FIG. 1 is a schematic flow chart of a lightweight hierarchical optimization design method for an automobile structure;
FIG. 2 is a schematic diagram of a back door structure soft constraint model interception method;
FIG. 3 is a diagram illustrating the result of optimizing the structural shape of the back door;
FIG. 4 is an integrated schematic diagram of the vibration performance analysis working condition of the lower back door of the whole vehicle;
fig. 5 is table 1.
Detailed Description
The invention is further explained by taking a backdoor structure as a design example of a research object and combining the attached drawings.
As shown in fig. 1, according to the lightweight hierarchical optimization design method for the automobile structure, firstly, a finished automobile finite element model is built, modeling quality is checked through finished automobile modal analysis, and then first-level optimization and second-level optimization are developed based on the finished automobile finite element model; the first-level optimization is structural optimization based on the performance indexes of the research objects in a soft constraint state, and the second-level optimization is parameter optimization based on the performance indexes of the whole vehicle;
the first-level optimization comprises a first step, a second step, a third step and a fourth step, and specifically comprises the following steps:
firstly, intercepting a research object on a finite element model of a finished automobile, and constructing a soft constraint model;
the interception method of the soft constraint model comprises the following steps: as shown in figure 2, a plane formed by the back door hinge and the lock catch center is taken as a reference, 200mm is cut in the direction of the vehicle head, and 1 in figure 2 is a model cutting plane. Wherein the soft constraint model constrains 1 to 6 degrees of freedom at the truncation interface. The soft constraint model includes three parts: a back door (comprising structures such as an inner decoration, a balance weight and the like, and a model is consistent with the state of the whole vehicle), a vehicle body back door frame, a back door and a vehicle body connecting piece. After interception, the boundary freedom degree of the backdoor is restrained by real parameters, namely the backdoor and a vehicle body connecting piece are restrained, and the real measurement parameters are assigned by a hinge, a lock catch, a sealing strip, a buffer block and a supporting rod respectively. The soft constraint refers to the constraint of the boundary freedom degree assignment real parameter of the research object.
Step two, establishing a topological optimization design space based on the soft constraint model in the step one, performing topological optimization analysis by taking the performance index of a research object as a constraint condition and taking the minimum quality as an optimization target, finding the optimal material distribution in the design space, reserving the material of a key part, and removing the material of a non-key part; in the topology optimization Material Model of this embodiment, a density method (SIMP) provided by OptiStruct software is adopted, that is, "cell density" of each cell of the finite element Model design space is used as a design variable. The unit density is continuously evaluated between 0 and 1, and after the optimization solution, the unit density of 1 (or close to 1) represents that the material at the position of the unit is important and needs to be reserved. A cell density of 0 (or close to 0) means that the material at the location of the cell is not important and can be removed, thereby achieving efficient use of the material and achieving light weight.
For the backdoor structure, the specific implementation scheme of the second step is that a topological optimization design space is established based on the soft constraint model in the first step, and a designable and changeable area of the backdoor inner plate is used as a topological optimization design space (the backdoor outer plate is a modeling surface and can not be changed); designing variables: cell density of the design space; constraint conditions are as follows: the bending mode of the back door is less than or equal to the target value, and the torsion mode of the back door is less than or equal to the target value; the optimization target is as follows: the soft constraint model has the minimum total mass. And performing topology optimization analysis, and reading an optimization solution result. Finding the optimal material distribution in the design space, reserving the material at the unit position (key part) with the unit density close to 1, removing the material at the unit position (non-key part) with the unit density close to 0, obtaining the material distribution condition of the design area of the inner plate of the back door, and identifying the force transmission path in the design space. And based on the topological optimization result, performing engineering modeling on the back door inner plate again, namely updating the design data of the back door inner plate based on the topological optimization result.
Step three, optimizing the shape of the soft constraint model optimized in the step two, and optimizing the structural shape of a research object;
and after the second optimization step, removing materials of non-critical parts on the inner plate of the back door to form holes, and determining the shape of the holes with the optimal performance by moving or deforming the nodes of the finite element grid to a new position, which is equivalent to changing the CAD design of the structure and deforming the grid and the nodes.
Specifically, the free shape is optimally set based on the OptiStruct software as follows:
designing variables: all nodes at the edge of the hole; constraint conditions are as follows: the bending mode of the back door is less than or equal to the target value, and the torsion mode of the back door is less than or equal to the target value; optimizing the target: the soft constraint model has the minimum total mass. And (3) executing optimization solution, obtaining an optimized structure through grid and node deformation, and determining the shape of the hole with the optimal performance by applying the optimized structure, wherein the result is shown in fig. 3, and 2 is the optimized hole.
And step four, performing strain energy analysis on the soft constraint model optimized in the step three, setting an analysis frequency range or modal order, and outputting a strain energy analysis result after solving is completed. Finding out a region with concentrated strain energy in the soft constraint model, and carrying out structural optimization on the region with concentrated strain energy; specifically, Strain Energy analysis is performed on the soft constraint model optimized in the third step, the modal analysis frequency range is set to be 0-80Hz, and an output Strain Energy result is set (the parameters are set to be ESE = ALL, Element Strain Energy). After the parameters are set, performing strain energy analysis, checking a strain energy analysis result, determining a region in the model where strain energy is concentrated, wherein the region where strain energy is concentrated is a weak part of the structure, and then optimizing the region where strain energy is concentrated.
In this embodiment, the area is concentrated to the strain energy is back of the door inner panel middle part region and hasp below profile transition region, and the method of improving strain energy and concentrating and adopting includes: (1) the local deformation resistance is increased by adding the reinforcing part in the middle area of the inner plate of the back door; (2) and aiming at the situation that the strain energy is concentrated in the profile transition area, the transition area is adjusted to be in smooth transition. Through strain energy analysis, the obvious weak part existing in the structural design is improved.
The second level optimization comprises a step 1, a step 2 and a step 3, and specifically comprises the following steps:
And 2, establishing a transfer function of a control factor and an output performance based on a polynomial response surface method according to the simulation analysis result in the step 1, and performing precision verification on the transfer function by using an error analysis method. And if the precision does not meet the requirement, returning to the step 1, increasing the sample size, and continuing to perform simulation analysis until the precision meets the requirement. Specifically, the transfer function is a functional relation between the material thickness parameter of the backdoor structural part and the vibration performance of the backdoor under the whole vehicle, and the precision of the transfer function QUOTE in the example
=99% (precision QUOTE is satisfied)
Decision conditions > 90%), it is determined that the precision of the constructed transfer function meets the optimization requirements.
And 3, based on the transfer function in the step 2, optimizing the control factor by adopting a simulated annealing algorithm by taking the output performance not more than the design target value as a constraint condition and the quality minimum as an optimization target to obtain an optimal solution, and calling a finished automobile finite element model to verify the optimal solution. If the simulation analysis result of the finite element model meets the design target value, the optimization is effective; otherwise, it is indicated that no solution meeting the performance requirement exists in the design space, the design space of the control factor in the step 1 needs to be properly increased, the step 1 is returned, and the optimization design is carried out again. In the example, an optimal solution is obtained based on the transfer function in the step 2, finite element model simulation verification is carried out, and the result of the optimal solution verification is found to meet a design target value (the maximum vibration value of the outer plate of the back door is 135 mm/s2 and is lower than a target value of 140mm/s 2), so that the optimization is effective, and meanwhile, the weight of the back door is reduced by 2Kg, and the purpose of light weight of the back door structure is achieved. Specific numerical values are shown in table 1 in fig. 5 below.
Claims (5)
1. A light-weight hierarchical optimization design method for an automobile structure is characterized in that,
firstly, building a finished automobile finite element model, and then developing first-level optimization and second-level optimization based on the finished automobile finite element model;
the first level of optimization comprises the following steps:
firstly, intercepting a research object on a finite element model of a finished automobile, and constructing a soft constraint model;
secondly, based on the soft constraint model in the first step, performing topological optimization analysis by taking the system-level performance index of the research object as a constraint condition and taking the minimum quality as an optimization target, and optimizing the material distribution of the research object;
step three, optimizing the shape of the soft constraint model optimized in the step two, and optimizing the structural shape of a research object;
step four, performing strain energy analysis on the soft constraint model optimized in the step three, finding out a region with concentrated strain energy in the soft constraint model, and optimizing the region with concentrated strain energy;
the second level of optimization comprises the steps of:
step 1, after the first-level optimization is completed, updating the parts or areas with changed design into a finished automobile finite element model, establishing an experiment plan by adopting a Hammersler sampling experiment design method and executing simulation analysis on the basis of the updated finished automobile finite element model, by taking the material thickness parameter of a research object as a control factor and the finished automobile-level related performance of the research object as output performance;
step 2, establishing a transfer function of a control factor and an output performance according to the simulation analysis result in the step 1;
step 3, based on the transfer function in the step 2, using the output performance not more than the design target value as a constraint condition and the quality minimum as an optimization target, adopting a simulated annealing algorithm to complete the optimization of the control factor to obtain an optimal solution, and calling a finished automobile finite element model to verify the optimal solution;
the study object is of a back door structure, the soft constraint model comprises a back door, a car body back door frame and a back door and car body connecting piece, the performance index of the study object comprises the bending mode and the torsion mode of the back door, and the material thickness parameter of the study object comprises the material thickness of an inner plate of the back door, the material thickness of an outer plate of the back door and the material thickness of a reinforcing piece; the whole-vehicle-level related performance of the research object comprises the vibration performance of a bottom back door of the whole vehicle;
after intercepting, the boundary freedom degree of the backdoor is restrained by real parameters, namely the backdoor and a vehicle body connecting piece are adopted for restraining, the backdoor and the vehicle body connecting piece are respectively a hinge, a lock catch, a sealing strip, a buffer block and a supporting rod, and the backdoor and the vehicle body connecting piece are assigned with real measurement parameters; the soft constraint refers to the constraint of the boundary freedom degree assignment real parameter of the research object.
2. The method for lightweight, hierarchical and optimal design of an automobile structure according to claim 1, wherein the second step is specifically as follows: and (3) establishing a topological optimization design space based on the soft constraint model in the step one, performing topological optimization analysis by taking the system-level performance index of the research object as a constraint condition and taking the minimum quality as an optimization target, finding the optimal material distribution in the design space, reserving the material of the key part, and removing the material of the non-key part.
3. The automobile structure light-weight hierarchical optimization design method according to claim 2, wherein the third step is specifically: and after the second step of optimization, removing materials of non-critical parts on the research object to form holes, and determining the shape of the holes with the best performance by moving or deforming the nodes of the finite element mesh to a new position and deforming the mesh and the nodes.
4. The method of claim 1, wherein in step four, the step of optimizing the region where strain energy is concentrated comprises adding a reinforcement to the region where strain energy is concentrated.
5. The method for lightweight, hierarchical and optimal design of an automobile structure according to claim 1, wherein the step 2 specifically comprises: and (3) establishing a transfer function of a control factor and an output performance based on a polynomial response surface method according to the simulation analysis result in the step (1), and performing precision verification on the transfer function by using an error analysis method.
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